As part of a major urban infrastructure rehabilitation, Fort Miller Group supplied 605 custom precast bridge deck panels for the Alexander Hamilton Bridge/Highbridge Interchange project—delivering precision, durability, and accelerated installation in one of NYC’s most complex highway networks.

Project Details

• Owner: New York State Dept. of Transportation, Region 11
• Contractor: Posillico Civil
• Engineer of Record: STV, Incorporated
• Completion Date: 2020
• Scope: 605 Deck Panels

Project Overview

Located at one of the busiest highway junctions in New York City, the Alexander Hamilton Bridge/Highbridge Interchange connects the Major Deegan Expressway (I-87) with the Alexander Hamilton Bridge (I-95), carrying over 120,000 vehicles per day. Originally constructed in the 1950s, this critical interchange needed extensive rehabilitation to meet modern safety standards and extend its service life.

To address these challenges with minimal traffic disruption, NYSDOT Region 11 launched a design-build contract to reconstruct three major ramp bridges. Fort Miller Group was selected to supply precast bridge deck panels, an ideal solution for this complex, urban infrastructure project requiring accelerated bridge construction (ABC) methods.

Scope and Details

This project required tight tolerances and precision fabrication to ensure seamless fit-up in a constrained urban environment. Fort Miller’s deep experience with prefabricated bridge systems and field-ready delivery logistics made them a critical partner in the project’s success.

Fort Miller fabricated and delivered 605 custom precast bridge deck panels for three ramp structures in the interchange. The ramps featured both radial and straight girders, demanding deck panels of varying shapes, including panels with warped geometry to accommodate elevation changes and tight vertical curves.

All deck units were cast at Fort Miller’s Easton, NY facility under strict quality control, incorporating steel reinforcement and post-tensioning as specified by NYSDOT. Each panel was engineered for precise geometry to fit curved alignments and complex super-elevation profiles.

Ultra-High Performance Concrete (UHPC) was used for panel joints, enhancing structural integrity, waterproofing, and long-term durability. The combination of custom geometries, UHPC joints, and high-strength materials will help extend the bridge’s service life by an estimated 75 years.

Panels were delivered within tight deadlines using specialized hauling equipment and installed during night and weekend closures, minimizing traffic disruption on the I-87/I-95 corridors.

Impact and Innovation

This design-build project exemplifies how precast bridge deck panels and accelerated bridge construction strategies can transform urban infrastructure rehabilitation.

The use of precast deck panels eliminated the need for prolonged traffic shutdowns. Crews were able to remove old decks and install new panels during overnight or weekend windows. Additionally, prefabrication and rapid installation reduced worker exposure to active traffic zones.

This project is a leading example of Fort Miller’s ability to meet the technical demands of large-scale design-build infrastructure, delivering quality precast solutions for high-impact transportation projects. 

From urban expressways to state-wide bridge initiatives, Fort Miller continues to set the standard in precast innovation. All bridge deck units were fabricated in Fort Miller’s Greenwich, NY, manufacturing facility and delivered to the site via specialized hauling equipment.